Modular plunger matrix mattress

ABSTRACT

A modular mattress includes several plunger matrix sections that each have a respective plunger matrix support platform. The several sections are configured for side-to-side assembly to form the complete matrix for the mattress. A foldable edge frame snugly receives and houses the plunger matrix sections in side-to-side relation. The edge frame also defines a flange on an internal surface of the edge frame that supports plunger matrix sections in side-to-side relation in a position allowing the plungers to move up and down within an internal space defined by the edge frame. A top pad lays on top of the edge frame and the plunger, while a cover configured encapsulates the edge frame, the plunger matrix, and the top pad into a self-contained mattress unit.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 61/728,565 entitled “Mattress Assemblies” filed Nov. 20, 2012;and U.S. Provisional Patent Application Ser. No. 61/825,748 entitled“Mattress Assemblies” filed May 21, 2013, and U.S. Provisional PatentApplication Ser. No. 61/879,437 entitled “Support Systems Including WaveSprings” filed Sep. 18, 2013; which are incorporated by reference.

BACKGROUND

The present disclosure generally relates to mattress assemblies and,more particularly, to mattress assemblies including a matrix ofindependently movable foam padded plungers.

Standard mattress designs have evolved very little in the past fiftyyears. A standard mattress generally includes a set of metal coilsprings mounted either on a base under a pad, or sandwiched between apair of pads. The metal springs and pad or pads are then covered with abatting material. The entire structure is then sewn into a cloth coverand the edges are wrapped and sewn. Thus, once the mattress isfabricated, the components are not replaceable. Due to the size andinherent firmness of the metal springs, spring-based mattresses exhibita limited ability to conform to a person's body contour, which isimproved only with great difficulty. While the independent coil springsare designed to compress under a person's body weight to match thesurface of the mattress to the contour of the person's body to someextent, many users still experience pressure points in certain bodylocations, particularly when not lying flat on their backs, leading tounnatural body positions and restless sleep.

The limitations of metal spring mattresses combined with improvedquality and durability of foam products has led to the relatively recentdevelopment of the foam core mattress as a viable alternative to thecoil spring mattress. A foam core mattress can provide significantimprovements in body contour, elimination of pressure points, andimproved comfort and support compared to conventional spring-basedmattresses. A basic foam mattress typically includes one or more layersof foam having desirable properties assembled into a fabric cover whichoften appears identical to a standard metal spring mattress. A foammattress may include a center core of relatively high resilience foamsandwiched between two layers of lower resilience foam encased in afabric shell. This construction allows for a reversible mattress.

While foam mattresses overcome some of the disadvantages of coil springmattresses, they exhibit other disadvantages including excessivefirmness, difficulty adjusting the firmness, and a lack of air flowthrough the foam core trapping body heat within the mattress. There is,therefore, a continuing need for improved mattress designs overcomingthe disadvantages of coil spring and foam mattresses.

SUMMARY

Embodiments of the present invention meet the needs described above in amodular plunger matrix mattress that includes a number of independentlymovable foam padded plungers that form an array of independently movablepoints of support. The plunger matrix mattress significantly improvesbody contouring over conventional coil spring mattress designs. Theplunger matrix mattress also allows substantial airflow through themattress improving over conventional foam mattress designs. Differentplungers may have different spring and dampening characteristics toallow different plungers and plunger zones of the mattress to exhibitdifferent firmness levels. In certain embodiments, individual plungersmay be removed and replaced independently, for example to replace theplunger with another plunger with a different spring or dampeningelement, and make other types of adjustments and repairs. A variety ofoptional design features and configurations provide for a wide range ofalternative configurations with differing levels of sophistication andfunctionality that can be deployed in a variety of combinations toproduce a range of models designed to meet differing customerpreferences and price points.

In a particular embodiment, the modular mattress includes severalplunger matrix sections that each have a respective plunger matrixsupport platform. The several sections are configured for side-to-sideassembly to form the complete matrix for the mattress. A foldable edgeframe snugly receives and houses the plunger matrix sections inside-to-side relation. The edge frame also defines a flange on aninternal surface of the edge frame that supports plunger matrix sectionsin side-to-side relation in a position allowing the plungers to move upand down within an internal space defined by the edge frame. A top padlays on top of the edge frame and the plunger, while a coverencapsulates the edge frame, the plunger matrix, and the top pad into aself-contained mattress unit.

The disclosure may be understood more readily by reference to thefollowing detailed description of the various features of the disclosureand the drawings included therein.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The Figures provide various embodiments and components of a plungermatrix mattress providing a large number of independent suspensionpoints.

FIG. 1 is a perspective view of a first illustrative embodiment of theplunger matrix mattress.

FIG. 2 is a side view of a person lying on a second illustrativeembodiment of the plunger matrix mattress.

FIGS. 3A and 3B are conceptual illustrations of plunger matrix mattressillustrating different firmness zones.

FIG. 4 is an exploded view of the first illustrative embodiment of theplunger matrix mattress.

FIG. 5 is a perspective view of the second alternative embodiment of theplunger matrix mattress with foam side sections.

FIG. 6 is an exploded view of the second illustrative embodiment of theplunger matrix mattress

FIG. 7 is a perspective view of a third alternative embodiment of theplunger matrix mattress with a foam perimeter.

FIGS. 8A-8E are views of example patterns for an edge frame or edgecover of the plunger matrix mattress.

FIGS. 9A-9H are perspective views of alternative foam heads for theplungers of the mattress.

FIG. 10 is a perspective view of an alternative mattress embodimentincluding a combination of a plunger matrix and coil spring sections.

FIGS. 11A-11C are perspective views of alternative plunger designs forthe plunger matrix mattress.

FIG. 12 is an exploded view of an illustrative plunger design for theplunger matrix mattress.

FIGS. 13A-13D are views showing alternative plunger pin guide designsfor the plunger matrix mattress.

FIG. 14 is a sectional view of a first illustrative plunger in its fullyraised position.

FIG. 15 is a sectional view of the first illustrative plunger in a fullylowered position.

FIG. 16 is a sectional view of a second illustrative plunger with aheight adjustment collar in a fully raised position.

FIG. 17 is a sectional view of the second illustrative plunger with aheight adjustment collar in a fully lowered position.

FIG. 18 is a sectional view of a third illustrative plunger with dualtension springs in a fully raised position.

FIG. 19 is a sectional view of the third illustrative plunger with dualtension springs in a partially lowered position.

FIG. 20 is a sectional view of the third illustrative plunger with dualtension springs in a fully lowered position.

FIGS. 21A-21C show alternative variegated plunger matrix designsutilizing plunger heads having different sizes and shapes.

FIG. 22 is a perspective diagram showing a modular plunger matrixmattress configured for convenient shipping as disassembled components.

FIGS. 23A-23D are perspective diagrams illustrating a customer assemblyprocedure for the modular plunger matrix mattress.

FIGS. 24A-24C are side views of a folding plunger matrix mattressconfigured for use with a mechanically adjustable bed frame.

DETAILED DESCRIPTION

Embodiments of the present invention may be realized in a modularplunger matrix mattress providing an array of independently movablepoints of support that significantly improve body contouring and supportover conventional coil spring mattress designs. Unlike conventionalmattresses, the plunger matrix mattress provides users with improvedsupport when the user is not lying flat on the mattress. Whileconventional mattresses give support when the user is lying on theirback, the support becomes very uneven when the user is not lying flat,for example when lying on their side, on a pile of blankets or on apillow. The plunger matrix system affords a much greater range ofvertical deflection, which enables the mattress to properly align theuser's body even when the user is lying on an obstruction or otherwisein an unnatural position. The plunger matrix mattress also allowssubstantial airflow through the mattress improving over conventionalfoam core mattress designs.

Unlike conventional mattresses, the individual plungers may beconfigured with different springs, plunger heads, and dampening elementsto provide plungers or plunger zones with differing firmnesscharacteristics. Individual plungers may also be removed and replacedindependently to change the firmness characteristic of individualplungers and make other types of adjustments and repairs after themattress has been manufactured. Different plungers with differentsprings, heads and dampening elements exhibiting different firmness andother characteristics may be arranged into a wide range of differentsupport zones exhibiting different, customizable support profiles. Forexample, zones with different firmness may be provided for head,shoulder, back, bottom, and leg sections of the mattress. Each mattressmay have a custom support profile specified by the customer. In mattressdesigned for two persons, independent side-by-side support profiles maybe configured for each person sharing the mattress. Plunger matrixdesigns may be incorporated into flat mattresses as well as foldingembodiments designed for mechanically adjusting bed frames.

In one embodiment, the mattress includes a matrix of independentlymovable foam padded plungers, a mattress pad on top of the plungers, aframe, and a rigid plunger support platform supported by the frame. Theplungers are individually suspended from the plunger platform and springloaded to provide an independent point of support. Each plunger includesa pin configured to move up and down within a pin guide that is receivedwithin a corresponding aperture through the plunger support platform. Atension spring captured on the pin guide urges the plunger upward whileallowing the pin to move downward in response to weight applied to thetop of the plunger. An edge frame may surround the plungers or theportions of the plungers extending above the plunger platform to provideadditional support at the edges of the mattress. Foam blocks or sectionsof coil springs may also be included along one or more edges of themattress to provide additional edge support.

In a particular embodiment, nested coil springs are combined on aplunger to provide a non-linear spring characteristic. As anotheroption, different plunger may be configured with different heightadjustment collars to adjust the maximum travel and springcharacteristic of the plunger. A wide range of different plunger headshapes and sizes may be combined to create a variety of mattressconfigurations. For example, a variety of foam caps configurations maybe utilized within the same mattress, such as hexagonal, dome shaped,tessellation geometries, and designs with various protrusions on the topsurface to provide massage sensation and compelling aesthetic designs.The plunger may also include a dampening device, such as a foam collararound the shaft of the pin above plunger support platform to provide anon-linear load-deformation response and/or dampen the spring action ofthe plunger. The foam collars, which may be removed by way of alongitudinal slit though the collar or by removing the pin from theplunger, may be unitary or segmented with different foam sectionsexhibiting different levels of firmness. The foam collar segments mayhave varying materials, density, height, width and othercharacteristics. In a particular design, for example, the segmentedcollar may include sections exhibiting progressive firmness. As anotheralternative, the dampening device may be a coil spring, which may belocated under a cover and combined with a foam component to reduce noiseand improve the dampening effect.

Various embodiments of the mattress may include a cover or perimeterencasement having a webbed, foam encasement, polyurethane orpolyethylene foam or other suitable construction. The mattress may belocated within a zip-on or other type of cover to encapsulate andprotect the internal mattress assembly. In this particularconfiguration, the plungers are located within the envelope of themattress. In other designs, the plungers may extend below the bottomsurface of the mattress into the foundation below. A variety ofselectable covers may be provided, such as waterproof covers, washablecovers, covers with extra batting, decorative designs, and so forth.

A particular alternative has a modular design including a sectionedplunger matrix, folding edge frame, top pad and zip-on cover configuredfor shipping in several cartons. Another embodiment includes asegmented, folding plunger matrix configured to flex on top of amechanically adjustable frame. A variety of foam block, coil spring,plunger design, edge frame, plunger head, mattress zone, replaceableparts, and other optional features provide for a wide range ofalternative designs with differing levels of sophistication andfunctionality that can be deployed in a variety of combinations toproduce a range of models designed to meet differing customerpreferences and price points. For all embodiments described below, arange of details and optional features, such as foam layers, membranes,vents, component covers, vibration dampeners, shock absorbers and thelike have been omitted to avoid cluttering the diagrams and may beincluded as standard or optional features.

Turning now to the figures, FIG. 1 is a perspective view of a simplifiedembodiment of the plunger matrix mattress 10 illustrating certain basiccomponents of a typical mattress. The assembly includes a foam cover 12on top of a matrix of plungers 14 surrounded by an edge frame 15. Arepresentative plunger 16 is enumerated to aid in the description. Theplunger and edge frame assembly is typically located within a cover orskirt 17 that provides a perimeter encasement to protect and may addstructural integrity to the mattress. The cover typically includes ventsor a breathable material to provide air flow through the mattress. Whilea webbed edge frame 15 is illustrated, the edge frame and perimeterencasement may be constructed of any suitable material having a range ofdesired configurations, such as polyurethane, polyethylene foam,structural plastic, or other suitable construction. The perimeterencasement may also employ conventional batting and fabric covering togive the plunger matrix a similar appearance to a conventional coilspring matrix.

FIG. 2 is a side view of a person lying on an alternative plunger matrixmattress 20 illustrating independent plunger movement to the contour ofthe person's body. The basic elements of the mattress 10 include the topfoam layer 12 and the matrix of independently spring-loaded plungers 14suspended by a plunger support platform 21, which is supported by asuitable frame component 22. In certain embodiments in which theplungers are located entirely within a self-contained mattress, theframe component 22 may be formed by a flange on the inside surface of anedge frame that surrounds plunger support platform. In otherembodiments, the frame component 22 may be part of a bottom frame thatallows the portions of the plungers located below the plunger supportplatform 21 to extend into the foundation provided by the bottom frame.

Referring to the illustrative plunger 16, the plunger is suspended by apin guide (not shown in this figure) that is captured within an aperturethrough the plunger support platform 21. The plunger 16 includes anupper foam head 23 carried on a plunger pin 24 that is captured withinthe pin guide. The pin moves up and down in the pin guide against thespring action of a tension spring 26 captured on the pin guide below theplunger support platform 21. A foam or other type of dampening collar 25positioned around the shaft of the plunger pin located above the plungersupport platform 21 is compressed during downward motion of the pin toprovide a non-linear load-deformation response and/or dampen the springaction of the plunger. This particular embodiment also includes foamblocks 28 a-28 b alongside the plunger matrix at the head and foot ofthe mattress.

The representative plunger 16 moves independently against its respectivetension spring 26 in response to weight exerted on the upper foam head23 to provide the mattress with a large number of independent points ofsupport for the person lying on the mattress. The plungers are designedto accept different springs, height adjustment collars, foam caps, andfoam or coil spring collars allowing different plungers to exhibitdifferent firmness, damping, depth of motion, and other characteristics.The full plunger matrix 14 may therefore include plungers with differentsprings, heads, and dampening elements to produce a configurable supportprofile 30. Plungers with different characteristics may be organizedinto a range of custom zones, which can be varied from mattress tomattress to accommodate different customer preferences.

Truly independent movement of the individual plungers through a muchlarger vertical range than conventional coil springs results in improvedbody contouring and comfort in comparison to conventional coil springmattresses. The relatively thin top foam layer 12 and the open nature ofthe plunger matrix 14 allow substantial air flow through the mattress incomparison to conventional foam mattresses. Each plunger may beindependently removed from the mattress after manufacture, and adifferent plunger configured with a different spring, dampening element,height adjustment element, or other design features may be inserted toprovide an alternative plunger exhibiting different levels of firmnessand other characteristics. The entire mattress is therefore configurablepost-manufacturing through removal and replacement of various plungersand other components to vary the support profile 30. It should be notedthat certain elements present in typical embodiments, such as an edgeframe, a frame supporting the plunger support platform, a pin guide foreach plunger, a cover or skirt over the mattress, and other details arenot shown for ease of illustration.

To provide an example of configurable support profile feature, FIG. 3Ais a conceptual view of support profile 32 for a twin mattress dividedinto five firmness zones. The firmness profile of the particular examplemattress is a standard twin mattress (e.g., 74.5 inches×38 inches) thatincludes a 10 inch long zone A (head zone), a 12 inch zone B (shoulderzone), an 8 inch zone C (back zone), a 12 inch zone D (bottom zone), anda 32.5 inch zone C (back zone). FIG. 3B is a conceptual view of a twoperson mattress (e.g., king or queen size) with firmness profile 34including two sets of zones A1-E1 and A2-E2 located side-by-side. Eachset of zones may exhibit different, customized support profiles for twopersons who share the mattress. While a wide range of zones withdifferent sizes, shapes and firmness characteristics may be configured,the zoning examples shown in FIGS. 3A and 3B are considered to besuitable as standard configurable zones for many users. It should benoted that the support profile of any particular mattress may be changedover time by swapping out or rearranging plungers or other components toaccommodate growth, weight or preference changes of the person using themattress.

FIG. 4 is an exploded view of a bed assembly 40 incorporating theplunger matrix mattress 10 shown in FIG. 1. The components of themattress assembly are shown generally to scale for a twin mattress. Thisfigure shows the plunger matrix 14 including the representative plunger16 received within a corresponding aperture 41 through a plunger supportplatform 21. The plunger matrix 14 is surrounded by the edge frame 15and the foam pad 12 sits on top of the plunger matrix 14. The cover 17in this example may be a skirt providing mattress with protection and apleasing outer appearance. A bottom frame 42, which may includeadditional cross bars and other conventional features, supports themattress 10. In the particular example shown in FIG. 4, the bottom frame42 includes a flange 44 that is sufficiently wide to underlie andsupport the edge frame 15 and an outer portion of the support platform21.

It should be appreciated that the plunger matrix may be realized in arange of different embodiments with the plunger support platformsupported in different locations in different embodiments. In theconfiguration shown in FIG. 4, for example, the plunger support platform21 and edge frame 15 are both configured to sit on the flange 44 of thebottom frame 42. In the alternative configuration shown in FIG. 6, theplunger support platform 21 and edge frame 15 are both configured to siton the frame board 66, which sits on the flange of the bottom frame 64.These configurations allow the plungers to extend into the foundationformed by the frames 42 and 62. In another configuration shown in FIG.22, the plunger matrix may be supported by a flange 225 on the inside ofthe edge frame 224 with the plungers positioned to move entirely withinthe envelope of an integral mattress. For this embodiment, one or moretop covers and zip-on envelopes may be included to add cushioning, holdthe components of the mattress together and lend structural to themattress as an integrated unit.

FIG. 5 is a perspective view of the alternative plunger matrix mattress20 including foam blocks 28 a and 28 b located alongside the plungermatrix 14 at the head and foot sections of the mattress. FIG. 6 is anexploded view of a mattress assembly 60 including the mattress 20 and aframe assembly 62. In this embodiment, the plunger matrix 20 issupported by the frame assembly 62, which includes a bottom frame 64 anda frame board 66 supported by the bottom frame. The frame board 66includes a window 68 sized to allow the plungers to extend through theframe board into the foundation provided by the bottom frame 64. Themattress 20 includes a foam top 12, foam blocks 28 a and 28 b, theplunger matrix 14 supported by the plunger support platform 21, and theedge frame 15 located under a cover 17. The edge frame 15 and theplunger support platform 21 both sit on the frame board 66, which sitson the bottom frame 64. In this particular embodiment, the edge frame issized to cover only the upper portions of the plungers above the plungersupport platform 21 with the bottom portions of the plungers extendinginto the foundation provided by the frame 62. The cover 17 may be askirt that allows the plungers to extend through the frame board. Thefoam blocks 28 a-28 b produce head and foot sections with increasedfirmness in those portions of the mattress where the desired bodycontouring is low. The foam sections also provide mattress sectionswhere a person may sit or stand without sinking excessively into themattress.

Many other mattress configurations may be designed with variouscombinations of plunger matrix sections, foam core sections, and coilspring sections. To provide another example to illustrate theadaptability of the design, FIG. 7 shows a mattress 70 with four foamblock edge sections 28A-28D. This configuration provides increasedfirmness around the full perimeter of the mattress, which may bedesirable for sitting on the edges of the mattress. Coil spring sectionsmay also be utilized for the edge sections or other areas of themattress. As another design option, coil spring may be utilized insteadof foam collars on the plungers for the entire plunger matrix or incertain areas of the mattress. As another option, a section of coilsprings may be placed on top of a foam block, and so forth, to createdifferent configurations to meet different price points and customerpreferences.

FIGS. 8A-8E are views of example edge patterns for the plunger matrixmattress. It should be appreciated that the edge of the mattress may bea structural frame (typically covered by a skirt or batting) or a zip-onenvelope depending on the particular design. FIG. 8A shows an edge frame15 with two-tiered lattice pattern 80 having an upper section 82 and alower section 84. The upper and lower sections each include two rows ofsinusoidal patterns in which the repeat pattern (sinusoidal wavelength)is shorter in the upper section than in the lower section. This designprovides greater firmness in the upper section 82 than in the lowersection 84 to provide a desirable support characteristic for a personsitting on the edge of the mattress. FIG. 8B shows an alternative ovallattice pattern 86, while FIG. 8C shows a diamond pattern 87. Otherembodiments may have a cover on the edge and include batting or anothersoft material under the exterior cover. For this type of embodiment,FIG. 8D shows a ventilation pattern 86, while FIG. 8E shows a clothexterior. These examples are merely illustrative and many other types ofedge patterns and external materials may be selected as a matter ofdesign choice.

FIGS. 9A-9F are perspective views of alternative foam heads for theplungers of the mattress to provide different shapes, contact profiles,massage textures, and desirable aesthetic configurations. FIG. 9A showsa hexagonal head 91 with a smooth surface, FIG. 9B shows a hexagonalhead 92 with relief slots, FIG. 9C shows a square or diamond shaped head93, FIG. 9D shows a square or diamond shaped head 94 with an integralcollar 95, and FIG. 9E shows a dome shaped head 96. Other heads may bedesigned to provide a massage or other tactile sensation. For example,FIG. 9F shows a hexagonal head 97 with protruding ridges, FIG. 9G showsa hexagonal head 98 with protruding dimples, and FIG. 9H a hexagonalhead 99 with a combination of protruding ridges and dimples. Differentmattress may include various combinations of head shapes, sizes, andsurface textures to provide a wide range of potential support pointconfigurations. The plunger heads may also be removed and replaced, asdesired, after the mattress has been constructed. Again, these examplesare merely illustrative and many other types of head patterns, textures,and materials may be selected as a matter of design choice.

FIG. 10 is a perspective view of an alternative mattress design 100 thatincludes a combination of a plunger matrix 101, a coil spring headsection 102, and coil spring foot section 103. To provide a specificexample, this alternative may be configured as a mattress with 230plungers in the matrix 101, 42 coil springs in the head section 102, and84 coil springs in the foot section 103. The mattress includes a sturdyframe 104 around the perimeter of structural foam or another suitablematerial. The coil springs of the head section 102 are supported by afirst foam base block 105 a, and the coil springs in the foot section103 are supported by a second foam base block 105 b. A platform supportframe 106 supports a plunger support platform 107, which suspends theplunger matrix 101 providing a sufficient space in the foundation formedby the support frame 196 to accommodate plunger movement. The entirestructure sits on a bottom panel 108 and is typically covered by askirt. It should be noted that certain details are omitted for ease ofillustration, such as a side panel of the foam frame 106, a side panelof the platform support frame 106, the top foam pad, the skirt to exposethe internal components, and other design details.

FIG. 11A is a perspective view of an illustrative plunger 16, whichincludes a hexagonal foam head 23, an internal movable pin 24, anexternal foam collar 25 on the upper portion of the pin, and a tensionspring 26. This figure shows additional features including a pin guide110 that includes a clip 112 represented by one arm of a two-arm clipenumerated in the figure for selectively securing the pin guide to theplunger support platform. The clips can be manually pinched to insertand remove the plunger from engagement with the plunger supportplatform. In an alternative embodiment that is not configured forremoving and replacing the plunger after the mattress has beenmanufactured, the plunger may not include a clip and may be permanentlyinstalled in the mattress. This particular embodiment also includes abushing 114 at the bottom of the tension spring 26 providing a dampeningand noise reducing support surface for the bottom of the spring 26. Asan optional feature, a number of selectable height adjustment collarsrepresented by the collars 116 a-116 c may be threaded onto the spring26 to constrain expansion of the portion of the spring captured by theheight adjustment collar. The height adjustment collar prevents aportion of the spring from expanding to alter the firmness and theextension length of the spring. The height adjustment collars withdifferent lengths 116 a-116 c may therefore be installed on the springto adjust the spring characteristic and depth of travel of the plunger.The height adjustment collar may include a stop that engages with theclip 112 on the pin guide 110 or another component when the collar hasbeen threaded to the top of the spring to prevent the height adjustmentcollar from backing off the spring during use of the mattress.

FIG. 11B is a perspective view of an illustrative plunger 16′ showing analternative configuration for the external foam collar surrounding theupper portion of the pin. This particular collar includes three sections117 a, 117 b and 117 c of differently configured foam blocks. Thedifferent blocks have different shapes, heights and widths. They mayalso exhibit different densities and be formed of different types ofmaterial. As an option, the sections may be configured to produce aprogressive dampening effect or progressive firmness on the pin as thepin moves downward. For example, the segmented foam collar may exhibit arelatively soft firmness during initial movement pin corresponding tocompression of primarily of the top layer 117 a, and then becomesincreasingly firm as the second layer 117 b is primarily compressed,with the third layer 117 c providing significantly firmer resistance toprevent the plunger from bottoming out during normal use.

FIG. 11C is a perspective view of an illustrative plunger 16″ in whichfoam collar surrounding the top portion of the pin has been replaced bya coil spring 118. The coil spring 118 is typically located within acover 119 to reduce noise and vibration. In various embodiments, a coilspring may be combined with one or more foam sections or layers tocustomize the spring rate response and dampening characteristics of theplungers. For example, a foam or other type of layer may be placed atthe top and bottom ends of the coil spring to reduce spring noise andsoften the feel.

FIG. 12 is an exploded view of the illustrative plunger 16 providing amore detailed view of the components. The components are shown generallyto scale for a plunger having a height of 12 inches. The foam head 23selectively attaches to a flange 120 on the pin 24, for example througha pocket on the bottom of the foam head that receives the flange on thetop of the pin. The pin moves up and down within the pin guide 110. Thefoam collar 25, which surrounds the top portion of the pin 24, iscaptured between the flange 120 of the pin and a flange 122 on the topof the pin guide 110 causing the foam collar to be compressed as the pinmoves downward within the pin guide. The spring 26 is fastened a springmount 123 (in this embodiment a robust thread) on the pin guide tofirmly hold the spring to the pin guide as the spring expands inresponse to weight applied to the top of the plunger. A first windowbearing 124 that snaps into the top of the pin guide 110 and a secondwindow bearing 126 that snaps into the bottom of the pin guide centerand stabilize the pin 24 as it moves within the pin guide. A cap 128 maysnap onto the bottom of the pin to provide dampening and spread theforce applied by the pin to the bottom of the spring. An additionaldampening bushing 114 may be captured on an axial spur on the end of thespring 26. The optional height adjust collar 116 may be threaded ontothe spring 26 to constrain expansion of a portion of the spring.

FIGS. 13A-13D illustrate various options for the pin guide. FIG. 13Ashows a pin guide 130 in which the window bearings have been replaced byextended bearings 131 a-131 b that snap into the pin guide body toincrease the support and stability provided to the pin. The shaft of thepin 24 has a “X” cross-section with four elongated fins in thisembodiment, and the extended bearings 131 a-131 b each include fourchannels that receive corresponding fins of the pin while allowing thepin to freely slide within the pin guide. FIG. 13B shows anotheralternative pin guide 132 in which the extended bearings have beenreplaced by four integral channels formed on the internal surface of thepin guide.

FIG. 13C illustrates a pin guide 135 configured to engage a pair ofnested tension springs. To support the springs in a nestedconfiguration, the pin guide includes two spring mounts 136 and 137configured to support respective upper ends of the nested springs. Inthis embodiment, the spring mounts are robust threads around the guidebody disposed in an axially tiered relation. As shown in FIG. 13D, anouter tension spring 138 is fixed to the outer thread 136, while aninner spring 139 is fixed to the inner thread 137. Although the specificspring selected may vary, the outer spring mount 136 generallycorresponds to the spring mount on a single-spring pin guide, and theouter spring 138 generally corresponds to the spring of thesingle-spring embodiment. In the dual-spring embodiment, the innerspring 139 is narrower and shorter than the outer spring with an upperend fixed to a second spring 137 that is just below and axially insetfrom the first spring mount 136 for the upper end of the outer spring138.

The sectional views of FIGS. 14-15 show the operation of thesingle-spring embodiment. FIG. 14 is a sectional view of the plunger 16of the single-spring embodiment with the pin 24 in its upper position.The foam head 23 is positioned on top of the pin 24, the pin is slidablyreceived within the pin guide, and the pin guide 110 is captured withinthe aperture 41 through the plunger support platform 21. The foam collar25 is captured between the flange 120 on the top of the pin 24 and theflange 122 on the top of the pin guide 110 to provide a non-linearload-deformation response and/or dampen the spring action of theplunger. The spring 26 is fastened to the thread 123 on the pin guide110. There is a cap 128 on the bottom of the pin 22 and a flexiblebushing 114 engaged with a spur on the bottom of the spring 26. FIG. 15is a sectional view of the plunger 16 in the fully lowered position. Thepin 24 has moved downward with respect to the pin guide 110, the foamcollar 25 has been compressed to provide a non-linear load-deformationresponse and/or dampen the spring action, and the tension spring 26 hasexpanded.

The sectional views of FIGS. 16-17 show the operation of thesingle-spring embodiment with a height adjustment collar. FIG. 16 is asectional view of the illustrative plunger 16 with a height adjustmentcollar 116 in a fully raised position. The height adjustment collar isthreaded onto the spring 26 to constrain expansion of an upper portion162 of the spring, while allowing only a bottom portion 164 of thespring to expand with movement of the pin 24. FIG. 17 is a sectionalview of the plunger 16 in the fully lowered position. The upper portion162 of the spring 26 is not expanded due to the height adjustment collar116, while the bottom portion 164 of the spring has expanded. The foamcollar 25 has been compressed, but to a lesser extent than in FIG. 15without the height adjustment collar. As noted previously, heightadjustment collars with different lengths may be utilized to adjust thespring characteristic and pin travel length of the plunger.

The sectional views of FIGS. 18-20 show the operation of a dual-springembodiment. FIG. 18 is a sectional view of an alternative plunger 180with dual tension springs 138, 139 in a fully raised position. Thenested coil springs provide the plunger with a nonlinear springcharacteristic by tensioning only the outer spring springs 138 during afirst portion of the downward motion of the pin 24, and then tensioningboth springs 138, 139 during subsequent downward motion of the pin. Theplunger may be similar to the illustrative plunger 16 describedpreviously except for the utilization of a dual-spring pin guide 135,the nested tension springs 138 and 139 (see also FIGS. 13C-13D) and anelongated slot 182 provided in a fin of the movable pin 24, whichtypically has a shaft with an X shaped cross-section with four elongatedfins. The slot 182 extends along a bottom portion of the shaft of thepin, for example about a third of the way up the shaft. The outertension spring 138 is fixed to an outer thread 136 and the inner tensionspring 139 is fixed to an inner thread 137 on the dual-spring pin guide135. A spur 184 on the end of the inner spring 139 is slidably capturedwithin the slot 182, which allows the spur to slide freely within theslot during a first portion of the downward travel of the pin. The slot182 therefore accommodates stretching of only the outer spring 138(without stretching the inner spring 139) during an initial portion ofthe downward travel of the pin 24 until the point where the top of theslot 182 reaches the spur 184 of the inner spring as shown in FIG. 19.

As a result, the bottom of the pin 24 stretches the outer spring 138throughout the entire downward travel of the pin, while the spur 184 atthe bottom of the inner spring 139 slides freely within the slot 182during an initial portion of the downward motion of the pin. The outerspring 138 is therefore tensioned by the full range of travel of the pin24, while the inner spring 139 is only tensioned during a portion of thedownward motion of the pin. That is, the inner spring 139 is nottensioned during the initial downward travel of the pin 24 while thespur 184 at the bottom of the inner spring 139 slides freely within theslot 182. FIG. 19 shows the point at which the pin 24 has moved downwarda sufficient amount to cause the spur 184 to become the engage with thetop of the slot 182, causing the inner spring to be tensioned by furtherdownward motion of the pin. FIG. 20 shows the point at which the pin 24has moved down to its fully lowered position with both springs 138, 139tensioned. As a result, only the outer spring 138 is tensioned duringthe first portion of downward movement of the pin 24, while both theouter and the inner spring 138, 139 are tensioned during a secondportion of downward movement of the pin.

FIGS. 21A-21C show alternative variegated plunger matrix designsutilizing plunger heads having different sizes and shapes. FIG. 21Aillustrates a variegated plunger matrix design 210 with square ordiamond shaped plunger heads of differing sizes. FIG. 21B illustrates avariegated plunger matrix design 212 with plunger heads that differ inboth size and shape. FIG. 21C illustrates a variegated plunger matrixdesign 214 with tessellate plunger heads that differ in both size andshape. Each design is typically configured with zones of plungers havingdifferent springs and damping characteristic to provide a customizedsupport profile. In these examples, the different areas having similarplunger heads may represent zones with different springs and dampingcharacteristics and the different head shapes may be designed to aid inproducing a desired support profile. It will be appreciated that theseexamples are merely illustrative and that that may variegated plungermatrix designs using a wide range of plunger shapes and sizes may bedeveloped as a matter of design choice. The variegated plunger matrixsections may also be combined with coil spring and foam block sectionsto further vary the design options.

FIG. 22 is a perspective diagram showing a modular plunger matrixmattress 220 configured for convenient shipping as disassembledcomponents. The plunger matrix is configured as three sections 222 a,222 b and 222 c designed to be placed side-by-side to create a standardsize mattress. Each plunger matrix section includes a respective plungersupport platform 223 a, 223 b and 223 c, which may be configured withinterlocking structures or fasteners to secure the sections together.The plunger matrix sections are sized to fit snugly within an edge frame224 that includes a flange 225 to support the plunger support platformsin a central location of the edge frame. A top pad 226 is configured forplacement over the top of the edge frame housing the plunger matrixsections. Foam layer 228 is designed to go over the plunger matrix, edgeframe and top cover to protect and add structural stability to theself-contained mattress. A variety of selectable zip-on covers may beprovided to go on top of the foam layer 228, for example to provide awater proof cover, a washable cover, additional batting, or a desiredouter appearance of the mattress. Each plunger matrix section 222 a, 222b and 222 c may typically be shipped in a respective box, while the edgeframe 224, foam pad 226, foam layer 228 and any additional coversordered by the customer may typically be shipped in a separate box, tocreate a multi-box (in this example four boxes) modular mattress thatcan be conveniently shipped by postal or parcel delivery service.

FIGS. 23A-23D are perspective diagrams illustrating a customer assemblyprocedure for the modular plunger matrix mattress 220. The customerunfolds the edge frame 224 and inserts the plunger matrix 222 a, 222 band 222 c in place with the plunger support platforms located on theflange 225 of the edge frame as shown in the series of diagrams 23A-C.The customer then places the foam pad 226 on top of the plunger matrixand zips one or more envelopes represented by the layer 228, typicallyincluding at least a foam layer and an outer cover, over the assembly asshown in FIG. 23D. The foam pad 226 in this example includes a number oflattice covered ventilation windows represented by the enumerated window230. The outer cover is typically constructed from a sturdy, breathable,machine washable fabric. The cover may also include similar or othersuitable types of ventilation structures.

Each plunger matrix section is configured for shipping within arespective box, while the edge frame is configured to be folded forshipping within a separate box. The top pad and cover are alsoconfigured to be folded or rolled and placed within the same box as theedge frame to create a multi-box shipping configuration for the modularmattress assembly.

FIGS. 24A-24C are side views of a folding plunger matrix mattress 240configured for use with a mechanically adjusting bed frame. FIG. 24A isa side view of the assembled mattress, which may be configured as amodular unit similar to the mattress 220 described with reference toFIG. 22. The basic elements of the mattress are a cover 241, a top pad242 and a mattress assembly including an edge frame (not shown) and aplunger matrix 243. FIG. 24B is a side view of the plunger matrix 243,which is configured as four sections 244 a-244 d connected by flexibleconnectors 246 a-246 c. FIG. 24C illustrates the flexible connectorsallowing the plunger matrix to flex to accommodate a mechanicallyadjusting bed frame. The connectors may be configured to slide onto theplunger matrix platform sections and may be secured in place by the edgeframe as well as other suitable fasteners or cooperating structures.

For all of the embodiments described above, a range of specificmaterials may be utilized for the various components, which maygenerally be varied in size, shape and other characteristic withinranges of suitable parameters as matters of design choice. The followingmaterial specifications are provided for certain representativeembodiments to aid in enablement and, while they are intended to besuitable for representative embodiments, the invention is not limited tothese particular materials or embodiments.

Referring to FIGS. 4 and 6, in a particular embodiment exhibitingdesirable weight, cost, strength, and ease of assembly characteristics,the top pad 12 may be constructed from standard polyurethane foam (PUF),viscoelastic PUF, latex foam, PUF with gel components, PUF with a phasechanging material (PCM), polyethylene foam (PEF), reticulated foam orother suitable materials. The edge frame 15 may be constructed from PUF,PEF, thermoplastic polymers or other suitable materials. The cover 17may be constructed from fabric, such as a woven or knitted fabricincluding fibers made of polypropylene, polyester, Rayon®, Modal®,Tencel®, cotton, wool or other suitable materials. The foam blocks 28 aand 28 b may be constructed from standard PUF, viscoelastic PUF, latexfoam, PUF with gel components, PUF with a PCM, PEF, reticulated foam orother suitable materials. The plunger support platform 21 and thesupport board 66 may be constructed from plastic, wood, aSintra®-polystyrene foam-Sintra® sandwich, bio-composite or anothersuitable material. The bottom frames 42 and 62 may be constructed fromwood, metal, plastic or another suitable material.

Referring to the combined plunger matrix and coil spring embodimentshown in FIG. 10, the coil springs in the head and foot sections 102 and103 may be coil springs typically utilized in mattresses. The foam frame104 may be Acetal®, Delrin® or another suitable material. The foam baseblocks 105 a and 105 b may be standard PUF, viscoelastic PUF, latexfoam, PUF with gel components, PUF with a PCM, PEF, reticulated foam,combinations of these components, or other suitable materials. Theplatform support frame 106 may be plastic, wood, a Sintra®-polystyrenefoam-Sintra® sandwich, bio-composite or another suitable material. Thebottom panel 108 may be a flame retardant nonwoven material, or othersuitable materials. This embodiment may include a top pad typicallyconstructed from PUF, viscoelastic PUF, latex foam, PUF with gelcomponents, PUF with a phase changing material (PCM), PEF, reticulatedfoam and/or other suitable materials and a skirt, such as a fireretardant (FR) knitted barrier or FR highloft nonwoven material, othertypes of woven or non-woven fabrics, or other suitable materials.

Referring to the illustrative plunger 16 shown in FIG. 12, the foam head23 may be a molded component constructed from PUF, PEF or other suitablematerials. The pin 24 typically includes a shaft with an X cross-sectionwith four elongated fins [approximately ⅛ inch thick] and may includereinforcing flanges along the fins to add rigidity. The pin 24 may beconstructed from ABS. The pin guide 110 and bearings 124, 126 may bemolded components constructed from Acetal®, Delrin® or another suitablematerial. The foam collar 25 may be a molded component constructed fromPUF, PEF or other suitable materials. The end cap 128 may be a moldedcomponent constructed from PUF, PEF or other suitable materials. Thebushing 114 may be a molded component constructed from Santoprene® othersuitable materials. The height adjustment collar may also be a moldedcomponent constructed from polypropylene, high density polyethylene orother suitable materials.

A variety of collars and springs may be employed to provide differentspring and dampening characteristics. To specify one example spring,which is necessarily varied within a range from the base specificationto implement customized support profiles, an plunger spring may have adiameter of 1.28 inches and a wire thickness of 0.056 inches. For adual-spring plunger, and additional inner spring may have a diameter of1.02 inches and a wire thickness of 0.061 inches.

In a particular embodiment of the modular mattress 220 shown in FIG. 22exhibiting desirable weight, cost, strength, and ease of assemblycharacteristics, the plunger support platforms 223 a-223 c may beconstructed from plastic, wood, a Sintra®-polystyrene foam-Sintra®sandwich, bio-composite or another suitable material. The edge frame 224may be constructed from PUF, PEF, thermoplastic polymers or othersuitable materials with side wall dimensions of 1 to 4 inches. The toppad 226 may be constructed from standard PUF, viscoelastic PUF, latexfoam, PUF with gel components, PUF with a PCM, PEF, reticulated foam orother suitable materials and may include other foam, batting andventilation elements as matters of design choice. The outer cover 228may be constructed from fabric, such as woven or knitted fabricincluding fibers made of polypropylene, polyester, Rayon, Modal, Tencel,cotton, wool or other suitable materials and may include ventilationcomponents as a matter of design choice. For the folding embodimentshown in FIGS. 24A-24C, the edge connectors 246 a-246 c may beconstructed from PUF, PEF, rubber or other suitable materials.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to make and use the invention. The patentable scope of the inventionis defined by the claims, and may include other examples that occur tothose skilled in the art. Such other examples are intended to be withinthe scope of the claims if they have structural elements that do notdiffer from the literal language of the claims, or if they includeequivalent structural elements with insubstantial differences from theliteral languages of the claims.

What is claimed is:
 1. A modular mattress assembly, comprising: aplurality of plunger matrix sections configured for side-to-sideassembly, each comprising a separate plunger matrix support platformsuspending a plurality of foam padded plungers; a foldable edge frameconfigured to snugly receive and house the plurality of plunger matrixsections in side-to-side relation, the edge frame defining a flange onan internal surface of the edge frame configured to support the plungermatrix sections in side-to-side relation in a position allowing theplungers to move up and down within an internal space defined by theedge frame, wherein each plunger comprises a dampening device comprisinga unitary foam collar, a segmented foam collar wherein each segmentexhibits a different firmness characteristic, a collar exhibiting aprogressive firmness characteristic, or a coil spring; a top padconfigured to lay on top of the edge frame and the plurality of plungermatrix sections in side-to-side relation housed within the edge frame;and a cover configured to encapsulate the edge frame, the plungermatrix, and the top pad into a self-contained mattress unit.
 2. Themodular mattress assembly of claim 1, wherein: each plunger matrixsection is configured for shipping within a respective box; the edgeframe is configured to be folded for shipping within a separate box; thetop pad and cover are configured to be folded or rolled and placedwithin the same box as the edge frame to create a multi-box shippingconfiguration for the modular mattress assembly.
 3. The modular mattressassembly of claim 1, wherein: each plunger matrix section is configuredfor shipping within a respective box; the edge frame is configured to befolded for shipping within a separate box; the top pad and cover areconfigured to be folded or rolled and placed within the same box as theedge frame to create a multi-box shipping configuration for the modularmattress assembly.
 4. The mattress assembly of claim 1, wherein theplungers organized into a plurality of zones defining a support profilein which the plungers of each zone are similarly configured while theplungers of different zones are configured differently to define avarying firmness characteristic of the support profile across the zones.5. The mattress assembly of claim 4, wherein the support profileincludes different firmness in head, shoulder, back, bottom, and legsections of the profile.
 6. The mattress assembly of claim 4, whereinthe zones are defined at least in part by one or more of differentspring types on plungers in different zones, different dampening deviceson plungers in different zones, or different height adjustment collarscaptured on the springs of the plungers in different zones.
 7. Themattress assembly of claim 4, wherein the zones are defined at least inpart by different plunger heads exhibiting one or more of differentmaterials, different shapes, or different sizes.
 8. The mattressassembly of claim 1, wherein at least a portion of the plungers haveheads with protrusions imparting a massage or other tactilecharacteristic to the heads.
 9. The mattress assembly of claim 8,wherein the protrusions comprise ridges, dimples, or a combination ofridges and dimples.
 10. The mattress assembly of claim 1, wherein eachplunger further comprises a clip for facilitating removal of the plungerfrom its respective plunger matrix section after the mattress has beenmanufactured.
 11. A mattress assembly, comprising: a plurality ofplunger matrix sections, each comprising a separate plunger matrixsupport platform, configured for side-to-side assembly; a foldable edgeframe configured to snugly receive and house the plurality of plungermatrix sections in side-to-side relation, the edge frame defining aflange on an internal surface of the edge frame configured to supportthe plunger matrix sections in side-to-side relation in a positionallowing the plungers to move up and down within an internal spacedefined by the edge frame, wherein each plunger comprises nested springscausing the plunger to exhibit a non-linear spring characteristic; a toppad configured to lay on top of the edge frame and the plurality ofplunger matrix sections in side-to-side relation housed within the edgeframe; a cover configured to encapsulate the edge frame, the plungermatrix, and the top pad into a self-contained mattress unit; wherein theplunger matrix sections define a support profile for a person lying onthe mattress comprising plungers organized into a plurality of zones inwhich the plungers of each zone are similarly configured while theplungers of different zones are configured differently to define avarying firmness characteristic of the support profile across the zones.12. The mattress assembly of claim 11, wherein the number of zones isgreater than the number of plunger matrix sections.
 13. A mattressassembly, comprising: a plurality of plunger matrix sections, eachcomprising a separate plunger matrix support platform, configured forside-to-side assembly; a foldable edge frame configured to snuglyreceive and house the plurality of plunger matrix sections inside-to-side relation, the edge frame defining a flange on an internalsurface of the edge frame configured to support the plunger matrixsections in side-to-side relation in a position allowing the plungers tomove up and down within an internal space defined by the edge frame; atop pad configured to lay on top of the edge frame and the plurality ofplunger matrix sections in side-to-side relation housed within the edgeframe; a cover configured to encapsulate the edge frame, the plungermatrix, and the top pad into a self-contained mattress unit; whereineach plunger comprises: a pin guide removably captured within anaperture through the plunger support platform comprising a flangepositioned above the plunger support platform, a guide body extendingfrom the flange through the aperture, a clip for facilitating removal ofthe plunger from its respective plunger matrix section after themattress has been manufactured, a pin slidably received within the pinguide comprising a flange located above the flange of the pin guide anda shaft extending from the flange through the guide body, a deformablehead carried by the flange of the pin; a tension spring having a firstend fixed to the guide body and a second end located below the guidebody positioned to receive a bottom end of the pin shaft, wherein thespring is configured to resiliently stretch with downward motion of thepin with respect to the pin guide, and a dampening device capturedaround the shaft of the pin between the flange of the pin and the flangeof the pin guide, wherein the dampening device is configured toresiliently deform with downward motion of the pin with respect to thepin guide.
 14. The mattress assembly of claim 13, wherein the plungermatrix sections define two different support profiles for two personlying side-by-side on the mattress.
 15. The mattress assembly of claim14, wherein each support profile includes different firmness in head,shoulder, back, bottom, and leg sections of the profile.
 16. Themattress assembly of claim 13, wherein each plunger further comprises aclip for facilitating removal of the plunger from its respective plungermatrix section after the mattress has been manufactured.
 17. Themattress assembly of claim 13, wherein the plunger matrix sectionsdefine a support profile for a person lying on the mattress comprisingplungers organized into a plurality of zones in which the plungers ofeach zone are similarly configured while the plungers of different zonesare configured differently to define a varying firmness characteristicof the support profile across the zones.
 18. The mattress assembly ofclaim 13, wherein the dampening device comprises a unitary foam collar,a segmented foam collar wherein each segment exhibits a differentfirmness characteristic, a collar exhibiting a progressive firmnesscharacteristic, or a coil spring.